Support bracket with small profile base for supporting an electrical junction box

ABSTRACT

A support bracket for securing a junction box to a support structure. The support bracket includes a brace member, a base member with two portions extending orthogonally from a first end of the brace member, and a flange extending orthogonally from a second end of the brace member. The flange includes two sides and ribs extending from the sides of the flange toward the base member. The base member includes a base flange extending from one side of the brace member and a bendable tab extending from an opposite side of the brace member. The base flange and bendable tab include apertures therein for receipt of fasteners. The flange includes a plurality of apertures therein for receipt of fasteners and a plurality of openings therein for connection of electrical conduit.

FIELD OF THE INVENTION

This invention relates to electrical junction boxes and specifically toa support bracket for an electrical junction box that enables mountingto a narrow support surface.

BACKGROUND OF THE INVENTION

In commercial buildings, electrical wiring is frequently routed throughrigid hollow conduit along the top of a top support member. The supportmember may be a C-beam, I-beam, angle beam or similar support structure.In order to provide electrical service to outlets, lights, and the like,the rigid hollow wall conduit is typically routed from the above the topsupport member to locations within the walls. The electrical codetypically requires wiring connections to be within junction boxes orsimilar protective enclosures and that the junction boxes be securelyanchored in place. In the past, junction boxes that were located abovethe top support member were frequently supported only by the rigidconduit that extended upward from the wall. Although brackets have beenproposed for anchoring such junction boxes, the brackets thus proposedtypically require a substantial area on the top of the support member inorder to be properly anchored thereto. In many situations, such as whenonly narrow support structures are available, the required substantialarea is not available for commercially available support brackets.

What is needed therefore is a support bracket with a small profile basefor supporting an electrical junction box. The base portion of thesupport bracket should include a small profile in order to occupyminimal space on a suitable support structure. The support bracket withsmall profile base will enable an installer to anchor a junction box toa wide range of support structures, including those that have a narrowtop surface or those that have only a narrow corner area exposed.

SUMMARY OF THE INVENTION

The invention is a support bracket for securing a junction box to asupport structure. The support bracket includes a brace member, a basemember with two portions extending orthogonally from a first end of thebrace member, and a flange extending orthogonally from a second end ofthe brace member. The flange includes two sides and ribs extending fromthe sides of the flange toward the base member. The base member includesa base flange extending from one side of the brace member and a bendabletab extending from an opposite side of the brace member. The base flangeand bendable tab include apertures therein for receipt of fasteners. Theflange includes a plurality of apertures therein for receipt offasteners and a plurality of openings therein.

OBJECTS AND ADVANTAGES

Several advantages are achieved with the support bracket of the presentinvention, including:

-   -   (1) The support bracket can be used to rapidly mount an        electrical junction box to a support member.    -   (2) The support bracket includes a small profile base that        requires minimal space on the support structure in order to be        installed.    -   (3) The support bracket will enable an installer to anchor an        electrical junction box to a wide range of support structures of        various sizes, including narrow surfaces or angular surfaces in        which only a narrow corner area is exposed.    -   (4) The support bracket enables the anchoring of a junction box        to a wide range of support structures, including C-beams,        I-beams, and L-shaped angle beams.

These and other objects and advantages of the present invention will bebetter understood by reading the following description along withreference to the drawings.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the support bracket of the presentinvention.

FIG. 2 is a front elevation view of a blank that will be shaped to formthe support bracket of FIG. 1.

FIG. 3 is a bottom view of the support bracket after being formed fromthe blank of FIG. 2.

FIG. 4 is a side view of the support bracket as viewed along line 4-4 ofFIG. 3.

FIG. 5 is a side view of the support bracket as viewed along line 5-5 ofFIG. 3.

FIG. 6 is a perspective view of a preferred embodiment of a supportbracket for an electrical junction box according to the presentinvention.

FIG. 7 is an exploded perspective view of the support bracket inposition to be secured to a support surface and in alignment with anelectrical box which it will support.

FIG. 8 is a perspective view of the support bracket attached to a beamand supporting an electrical junction box to which electrical conduithas been connected.

FIG. 9 is a side view of the support bracket of the present inventionattached to the top surface of a small beam and supporting an electricaljunction box.

FIG. 10 is a side view of the support bracket of the present inventionattached to the corner of a support surface and supporting an electricaljunction box.

INDEX TO REFERENCE NUMERALS IN DRAWINGS

20 support bracket, first embodiment

22 brace member

24 first end of brace member

26 second end of brace member

28 first side of brace member

30 second side of brace member

32 base member

34 flange

36 base flange

38 bendable tab

40 blank

42 first bend line

46 second bend line

48 C-shaped slot

50 centerline

52 central opening

54 opening

56 aperture in flange

58 aperture in base flange

60 aperture in bendable tab

62 side of flange

64 third bend line

66 strengthening rib

68 inner edge of rib

69 open area

70 electrical junction box

72 C-shaped beam

74 electrical conduit

75 fastener for securing support bracket to support structure

76 mounting hole of junction box

78 fastener for securing junction box to support bracket

80 knockout

82 side of junction box

84 back wall of junction box

86 nut

88 opening in junction box

90 L-shaped beam

Θ1 angle of flange with respect to brace member

Θ2 angle of base flange with respect to brace member

Θ3 angle bendable tab with respect to brace member

W1 width of base member

W2 width of flange

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1 there is shown a portion of a preferred embodimentof a support bracket 20 with a small profile base according to thepresent embodiment. The support bracket 20 includes a brace member 22with a first end 24 and second end 26 and a first side 28 and secondside 30. A base member 32 extends orthogonally from the first end 24 ofthe brace member 22 and a flange 34 extends orthogonally from the secondend 26 of the brace member 22. The base member 32 includes a base flange36 extending from the first side 28 of the brace member 22 and abendable tab 38 extending from the second side 30 of the brace member22.

With reference to FIG. 2, the support bracket of the present inventionis preferably stamped from a flat sheet of metal to form a blank 40. Theblank 40 includes a plurality of bend lines including a first bend line42 for bending the base flange 36 and the bendable tab 38 orthogonallywith respect to the brace member 22 and a second bend line 46 forbending the flange 34 orthogonally with respect to the brace member 22.The blank 40 includes a substantially C-shaped slot 48 lanced in theplanar brace member 22 which will form the bendable tab 38. The firstbend line 42 and second bend line 46 form a centerline 50 about whichthe base flange 36 and bendable tab 38 will be bent to form the supportbracket. The blank 40 further includes a plurality of circular openingsincluding a central opening 52 and outlying openings 54. A plurality ofapertures 56 are provided in flange 34 around central opening 52. Aplurality of apertures 58 are provided in the base flange 36 and anaperture 60 is provided in bendable tab 38. Flange 34 includes two sides62 and third bend lines 64 extending along flange 34 near the sides 62.The portion of the flange 34 outward of the third bend lines 64 is bentorthogonally with respect to the flange 34 to form strengthening ribs66. The ribs 66 include inner edges 68 adjacent the brace member 22 asshown.

Referring to FIG. 3, the support bracket 20 is shown after being formedfrom the blank of FIG. 2. Base flange 36, as viewed in FIG. 2, has beenbent upward 900 toward the viewer to form the support bracket 20 asshown in FIG. 3. As bendable tab 38 is lanced free of the brace member22 by the C-shaped slot 48, bendable tab 38 remains planar with baseflange 36 as base flange 36 is bent around first bend line 42. Thus, inthe support bracket 20, the base flange 36 extends in a first directionfrom the centerline 50 and the bendable tab 38 extends in a seconddirection with the base flange 36 and bendable tab 38 being 1800 aparton the support bracket 20. As shown in FIG. 3, the small profile basemember 32 includes a substantially narrow width W1, measured across thebase flange 36 and bendable tab 38, as compared to the width W2 offlange 34. The narrow base width W1 creates a small profile base 32 thatrequires minimal space on a suitable support structure (not shown) whenthe support bracket 20 of the present invention is secured thereto. Withreference to FIG. 2, flange 34 is bent 90° upward with respect to theviewer around second bend line 46 and the ribs 66 are also bent upward90° with respect to the viewer around each of the third bend lines 64 inorder to form the support bracket 20. Thus, in the support bracket 20,as viewed in FIG. 3, base member 32 is in a plane parallel to the planethrough flange 34.

As shown in FIG. 4, bendable tab 38 of support bracket 20 is orthogonalto brace member 22 thereby forming open area 69 in brace member 22. Asshown in FIG. 5, flange 34 is at angle Θ1 with respect to brace member22, base flange 36 is at angle Θ2 with respect to brace member 22, andbendable tab 38 is at angle Θ3 with respect to brace member 22. AnglesΘ1, Θ2, and Θ3 are each preferably 90°.

Referring to FIG. 6, the support bracket 20 is used to secure anelectrical junction box, such as conventional 4″×4″ junction box 70 to asupport structure. FIG. 6 illustrates the support bracket 20 of thepresent invention being used to secure a junction box 70 to a C-shapedbeam 72 to accommodate an electrical conduit 74. The invention isoperated by simply drilling holes in the support structure 72 inalignment with the apertures 58 in the base flange 36 and bendable tab(not shown) and securing the base 32 of support bracket 20 to the beam72 with fasteners 75. The mounting holes 76 of the junction box 70 arethen aligned with the flange apertures (not shown) of the supportbracket 20 and fasteners 78 are then used to secure the junction box 70to the support bracket 20. The support bracket 20 therefore providesproper support for the junction box 70 according to the electrical codeand prevents the unsafe condition of an electrical box being supportedsolely by the rigid wall conduit 74. Conventional junction box 70typically includes a plurality of knockouts 80 along its sides 82 andback wall 84 as shown. Fasteners 75 and 78 may be self-threadingfasteners as shown.

FIG. 7 depicts the operation of the support bracket 20 of the presentinvention including electrical box 70 in alignment to be secured to thesupport bracket 20 and support bracket 20 in position to be secured to asupport structure 72. Support bracket 20 in FIG. 7 is depicted beingsecured to C-shaped beam 72 with fasteners 75 through base flange 36 andbendable tab 38 and nuts 86. Apertures 58 in base flange 36 and aperture60 in bendable tab 38 are located at the outer periphery of the supportbracket 20 thereby making it easy for an installer to secure the bracket20 to the support structure 72 even if the 4″×4″ junction box 70 isfirst secured to the support bracket 20.

As shown in FIG. 8, after the electrical junction box 70 is secured tothe support structure 72, electrical conduit 74 can be routed into thejunction box 70 by removing one or more of the knockouts 80 to create anopening 88 for receiving the electrical conduit 74. Support bracket 20ensures that the electrical junction box 70 is properly securedaccording to the electrical code and is not merely supported by theelectrical conduit 74.

FIGS. 9 and 10 depict one of the particular advantages provided by thesupport bracket 20 of the present invention. The small profile basemember 32, including the base flange 36 and bendable tab 38, aresubstantially smaller in width than the electrical junction box 70.Thus, as shown in FIG. 9, the narrow base 32 enables an installer tosecure the 4″×4″ junction box 70 to a narrow structural support such asthe C-beam 72 shown. The support bracket 20 includes a small profilebase 32 that requires minimal space on a support structure in order tobe installed. As shown in FIG. 10, for a narrow structural support suchas the L-shaped angle beam 90 for which the base member 32 is largerthan the beam, bendable tab 38 can be bent to enable the base member 32to fit flush against the corner of the beam 90. Fasteners 75 are thendriven through base flange 36 and bendable tab 38 to secure the supportbracket 20 to the beam 90. The support bracket 20 therefore enables aninstaller to anchor an electrical junction box 70 to a wide range ofsupport structures of various sizes, including those having narrowsurfaces or angular surfaces in which only a narrow corner area isexposed.

The support bracket 20 of the present is preferably constructed ofmetal. Most preferably, the blank 40 (see FIG. 2) is stamped from0.040-inch thick AISI 1010 steel that has been galvanized to a minimumzinc plating thickness of 0.0005-inch.

Although the description above contains many specific descriptions,materials, and dimensions, these should not be construed as limiting thescope of the invention but as merely providing illustrations of some ofthe presently preferred embodiments of this invention. Thus the scope ofthe invention should be determined by the appended claims and theirlegal equivalents, rather than by the examples given.

1. A support bracket for securing an electrical junction box to asupport member comprising: a brace member including two ends and twosides; a base member extending from a first end of said brace member; aflange extending from a second end of said brace member; a base flangeextending from a first side of said brace member; and a tab extendingfrom a second side of said brace member.
 2. The support bracket of claim1 wherein said base member is orthogonal to said brace member; and saidflange is orthogonal to said brace member.
 3. The support bracket ofclaim 1 wherein said base member includes a centerline; said base flangeextends in a first direction from said centerline; said tab extends in asecond direction from said centerline; and said base flange and said tabare 180 degrees apart.
 4. The support bracket of claim 1 wherein saidbrace member is planar; and said tab is lanced out of a portion of saidbrace member.
 5. The support bracket of claim 1 including a plurality ofopenings in said flange including a central opening; and a plurality ofapertures surrounding said central opening.
 6. The support bracket ofclaim 1 wherein said flange includes two sides; and a rib extending fromeach of said sides of said flange toward said base member.
 7. Thesupport bracket of claim 6 wherein said rib includes an inner edge; andsaid inner edge of said rib is in contact with said brace member.
 8. Thesupport bracket of claim 6 wherein said rib extends orthogonally fromsaid flange.
 9. The support bracket of claim 1 wherein said supportbracket is stamped from a sheet of metal to form a blank; said blankincludes a substantially C-shaped slot in said brace member; and saidtab is formed by said C-shaped slot.
 10. The support bracket of claim 9wherein said blank includes a plurality of bend lines thereon forforming said support bracket; and said bend lines include a first bendline for bending said base flange and said tab orthogonally with respectto said brace member and a second bend line for bending said flange withrespect to said brace member.
 11. The support bracket of claim 1including a plurality of apertures in said base flange; and an aperturein said tab.
 12. The support bracket of claim 1 wherein said base memberincludes a substantially narrow width as measured across said baseflange and said tab.
 13. The support bracket of claim 1 wherein saidsupport bracket is constructed of metal.
 14. The support bracket ofclaim 13 wherein said metal is 1010 steel of at least 0.04-inchthickness; and said metal is galvanized with a minimum zinc platingthickness of 0.0005-inch.
 15. A support bracket for securing anelectrical junction box to a support member comprising: a brace memberincluding two ends and two sides; a base member extending from a firstend of said brace member; a flange extending from a second end of saidbrace member; a base flange extending from a first side of said bracemember; a tab extending from a second side of said brace member a ribextending from each of said sides of said flange toward said basemember, said rib including an inner edge; and said inner edge of saidrib is in contact with said brace member.